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Something catastrophic just happened!

Old 09-20-2017, 08:08 AM
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Hey, the worst that can happen is that 2x4 breaks up and the side gears slip out of their bearings, the axles will just run off center inside and maybe overstress the outer bearings. Who cares what happens to them now? I won't be going over 40 mph anyhow. The whole route is 52 miles including picking them up. The papers won't be over 250 lbs. Hell, I'm heavier than that!

That's the thing about the D35 though. There could be something wrong with it and you'll never know until it grenades! That cross pin was still in one piece except for the part above the bolt hole so the carrier casting must have cracked.

Bits and pieces. The chunk next to the pin is what broke out of the carrier casting. Part of it anyway. I got a couple of shivers cleaning of the magnet so I stopped trying to.

Last edited by dave1123; 09-20-2017 at 08:37 AM.
Old 09-20-2017, 08:21 AM
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Sounds right, all that backlash..never good. Bearings wear, backlash, little this little that and bam.
Um worst that could happen is your setup lets go and you cross lanes in front of a school bus. No wait.. I can think of even worse....
Old 09-20-2017, 08:40 AM
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Ain't going to happen! No schoolbuses out after 11 PM! There are a couple of fuel tankers though.....
Old 09-20-2017, 03:23 PM
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lovely pics I say take these parts and trade me your valvetrain parts and put it back together if thats the only piece from the carrier that broke..then again you said your backlash was out.
Old 09-20-2017, 04:08 PM
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Dave, I think you can tell us the truth now. You were really doing doughnuts in front of some guys house on your route that you dont like. You may be older/more mature then some of us but I know you still like to have fun. We wont tell anyone.
Old 09-20-2017, 07:41 PM
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Originally Posted by 97grand4.0
lovely pics I say take these parts and trade me your valvetrain parts and put it back together if thats the only piece from the carrier that broke..then again you said your backlash was out.
The carrier is cracked as well with pieces missing, turned into flakes. I know it's against better judgement to use it tonight, but it's better than doing a ride-along with my boss and listening to his criticism about why I do what I do.
Old 09-20-2017, 09:53 PM
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Originally Posted by dave1123
BTW, I can't get that smell off my hands, probably not until I shower.
If you have anything small made of stainless steel, try "washing" your hands with it. They actually make "stainless steel soap," which isn't soap but is just a bar of stainless steel in the shape of a bar of soap for getting smells off your hands. Some Bed Bath and Beyond stores carry this one:

https://www.bedbathandbeyond.com/sto...bar/1012829620

To get rid of onion, garlic and fish smells, my mom actually washes her hands with a big stainless butcher knife. Carefully. I've never tried it with gear oil, but it certainly does work with other smells.
Old 09-21-2017, 04:23 AM
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Ivory soap took care of it. It even cleaned out my nails! I used a brush on them. I've used Ivory in the shower for many years to get the smell of cutting oil off my body after coming home from work. I'd get that smoke all over me.

Interesting. I was in a hurry to get it back together and couldn't find my RTV so I just slapped the cover back on after cleaning it. I figured if it leaked, no harm done. IT DOESN'T LEAK! At least not yet. I am dumbfounded!

I'm thinking the reason for the backlash is because the carrier casting is cracked, which may have been the start of the failure. It's cracked enough that I think if I took it out and hit one end with a hammer, I'd have 2 pieces.

Your boss is right about vehicles used for delivering papers. They get a lot of abuse with all the stops, starts, turnarounds, and such. It's hard on brakes and transmissions especially. Tires get extra wear quickly and power steering pumps wear out frequently. As MY boss said "Anybody who thinks delivering newspapers is an easy job has never done it!" (Sorry, that was a conversation in a PM!)

Last edited by dave1123; 09-21-2017 at 04:26 AM.
Old 09-21-2017, 04:35 AM
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Originally Posted by 5-Speed
Dave, I think you can tell us the truth now. You were really doing doughnuts in front of some guys house on your route that you dont like. You may be older/more mature then some of us but I know you still like to have fun. We wont tell anyone.
Just because I USED to autocross and gymkhana doesn't mean I do it now! Although I'd love to take your bug for a lap or two! I used to play with the Corvettes in my 67 SS Camaro once in a while. I've taken 2nd in fastest-time-of-the-day a couple of times.
Old 09-21-2017, 07:50 AM
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Well guess I'll box this perfectly good set of carrier gears crosspin and bolt back up.
Hey Dave, wanna part with your rockers and pivots? I got $50 today, Ill pick up?

Last edited by 97grand4.0; 09-21-2017 at 02:08 PM.
Old 09-21-2017, 01:30 PM
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Originally Posted by dave1123
Just because I USED to autocross and gymkhana doesn't mean I do it now! Although I'd love to take your bug for a lap or two! I used to play with the Corvettes in my 67 SS Camaro once in a while. I've taken 2nd in fastest-time-of-the-day a couple of times.
If you ever find yourself out this way, you can take the Bug for a spin!
Old 09-21-2017, 04:07 PM
  #27  
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Originally Posted by 5-Speed
If you ever find yourself out this way, you can take the Bug for a spin!
I wouldn't trust myself with it! Thanks for the generous offer though. I'm 72 and my reactions are too slow to be capable to correct fast enough to avoid a catastrophe. And you KNOW I'd be pushing the limits, right? You can flat spin a Camaro. Can the bug?
Old 09-21-2017, 04:22 PM
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Originally Posted by 97grand4.0
Well guess I'll box this perfectly good set of carrier gears crosspin and bolt back up.
Hey Dave, wanna part with your rockers and pivots? I got $50 today, Ill pick up?
All I've got is the pivots so far! They were only $1.55 each! Mopars are $7.70 each. I figured I'd start with the pivots, taking a little at a time off them, then go back and replace everything when I figured out how much I had to work with before the lifters bottomed. I ballparked about 1 mm needs to be cut to make up for wear. I'll GIVE them to you if you want to do the research. As I said, they are super-hard, estimated at 60 or 65 Rockwell and even carbide would make a mess of them. It's probably the rockers that are worn the most. They are just heat treated stamped steel.

Near as I can figure, the only faults in the design of the 4.0 was the lack of adjustable valve lash and slipper pistons with minimal skirt depth.

Last edited by dave1123; 09-21-2017 at 04:30 PM.
Old 09-21-2017, 07:30 PM
  #29  
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Originally Posted by dave1123
All I've got is the pivots so far! They were only $1.55 each! Mopars are $7.70 each. I figured I'd start with the pivots, taking a little at a time off them, then go back and replace everything when I figured out how much I had to work with before the lifters bottomed. I ballparked about 1 mm needs to be cut to make up for wear. I'll GIVE them to you if you want to do the research. As I said, they are super-hard, estimated at 60 or 65 Rockwell and even carbide would make a mess of them. It's probably the rockers that are worn the most. They are just heat treated stamped steel.

Near as I can figure, the only faults in the design of the 4.0 was the lack of adjustable valve lash and slipper pistons with minimal skirt depth.
Ah no that's ok. Picking up just 2 rockers and pivots at napa tomorrow along with a pushrod. Picked up a stethascope for $10 at Advance. Gonna open her up, sounds like 1 rouge lifter maybe two, gonna use my vernier caliper and micrometers do some measuring. Hoping one of those will show up bad if so replace and then order the whole set. Other obvious dubious conclusion is the lifters are bad, but like I said they quiet right down after a minute or two. The one is getting worse tho recently. Also I checked for a bent bridge not long ago, there were a couple that were a bit out that I straightened. All in the torque down method. Alternate a couple turns at a time to not bend them.
Ill check the rockers against the new ones real close with the mics.
-And I hope Dave does you right out there. lol

Last edited by 97grand4.0; 09-21-2017 at 07:36 PM.
Old 09-21-2017, 08:06 PM
  #30  
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Yeah, check the rocker bores that the pivots slide into. That and the valve contact area is what to look at. IDK if the 4.0 has this problem, but SBCs had a habit of the pushrod sockets cracking, usually on engines that were taken up to valve float.

When I put the new head on mine, I put a new set of lifters in. I eyeballed the old lifters to make sure none of them were cupped on the bottom flat so I figured the cam was okay. The valves were quiet for a couple of days, then started rattling again. It's funny that they are totally quiet now after a good run at 60 until I shut it off, then rattle at idle on startup, even after just a few minutes.

You can eliminate the twisting of the bridges if you do the cylinders at TDC compression in the firing order, just like preloading hydraulic lifters on a Chevy. That way all you're compressing is the lifters, not the valve springs. It takes a bit of time though.

Last edited by dave1123; 09-21-2017 at 08:13 PM.

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